What you will do

build plugs (plastic replicas), and then produce patterns from materials such as wood, fibreglass and metal

make moulds

use new technology such as 3D printing and CNC pattern making

heat and melt metal and pour it into moulds or hammer and cut it to shape

remove castings from moulds when they have cooled

inspect, test and repair metal castings

temper, harden, polish and coat the final metal product.

Skills and knowledge

Metal workers need to have knowledge of:

metals, woods, clays, plastics and resins

technical plans and drawings

casting

sands, paints and coatings used in moulding

the use and care of metal working equipment.

Working conditions

Metal workers:

usually work regular business hours, but may be required to work overtime to meet deadlines

work in industrial workshops, or ferrous (iron) or non-ferrous (aluminium and brass) foundries

often work in hot, noisy and dusty conditions.

What's the job really like?

Des Hansen

Metal Worker

Des Hansen began his career as a truck driver, but embarked on a metal working apprenticeship after deciding he needed a change.

Now 20 years into his career, Des works as a moulding supervisor at a foundry in the South Island. He and his team cast a variety of products such as engine blocks, alloys, irrigation fittings for underground water mains and compressor components.

"We mainly use steel, cast iron, ductile iron and aluminium here. The most we can cast is about one tonne, but you need some pretty substantial sand moulds to hold that. The chemically bonded sands are pretty durable though - when they set they're just like concrete."

All the hard work's worth it

Des admits that he works in some pretty tough conditions. "It's a heavy job and you definitely have to be energetic. Having strength and stamina is really important."

But he's quick to point out that the job has its up-sides too.

"It's pretty hard to describe a typical day here because it varies all the time, and every day presents a new challenge. It's just brilliant.

"The best thing is seeing a big, tricky casting going out the door and knowing you've accomplished something."

Find out more about training

What are the chances of getting a job?

Decline in metal manufacturing limits opportunities

Chances of getting entry-level work as a metal worker are poor because:

some metal working companies have reduced staff and outsourced work to countries where production costs are lower

metals and metal products exports have flattened off due to increased international competition

Increase your chances of getting an apprenticeship

Although there are fewer entry-level positions available, a small number of apprentices are still taken on each year.

You can increase your chances of getting an apprenticeship by:

having some mechanical engineering or labouring experience

showing an interest and approaching employers directly.

Demand good for experienced metal casting workers

However, demand for experienced metal casting workers is good. This is because:

many metal casting workers are nearing retirement, and experienced metal casting workers are needed to replace them

many employers can't afford to train new staff - so when vacancies arise, they're likely to look for staff who require the least training

the construction sector boom, especially in Auckland and Christchurch, may stimulate demand for experienced metal workers.

As a result, metal casting trades worker appears on Immigration New Zealand's regional skill shortage list. This means the Government is actively encouraging skilled metal workers from overseas to work in New Zealand.